Modular conductor system

ABSTRACT

A modular conductor system for electrical circuit wiring. The system includes a composite insulated conductor assembly having first and second elongate members of substantially homogeneous electrically nonconductive material, each of the members having substantially uniform transverse dimensions and substantially planar ends. The first member includes a plurality of spacedapart channels each extending lengthwise of the member in a surface thereof. Electrically conductive members, each having a relatively thin substantially uniform cross section fit snugly lengthwise and conform to the surface of corresponding ones of the channels such that the side edges of the conductive members are substantially flush with the surface of the first elongate member. The second elongate member extends the length of the first, and has a surface secured to the surface of the first member in which the channels extend, confining the conductive members in the channels. A space between each of the conductive members and the surface of the second elongate member defines openings at the ends of the composite conductor. Relatively short electrically conductive connector pins are receivable in the openings for joining together a plurality of the composite conductor assemblies in electrically conductive relationship. Each of the connector pins has a cross section conforming to the cross section of the openings at the ends of the joined elongate members, the pins having rough surfaces such that they are tightly gripped in the openings. Various modules may be used with such composite conductor assemblies, e.g., a receptacle module, a switch module, connector modules, and a wiring adaptor module which connects the modular wiring system to wire conductors of a power distribution system.

United States Patent Chaney et al.

[54] MODULAR CONDUCTOR SYSTEM [72] Inventors: Larry R. Chaney,Bridgeton, Mo.; Edwin J. Coughlin, Rowland Heights, Calif.

[73] Assignee: Contecknix, Inc., St. Louis, Mo. [22] Filed: May 4, 1970[2l] Appl. No.: 34,149

Primary Examiner-Marvin A. Champion Assistant Examiner- Robert A. HaferAtrorney-Koenig, Senniger, Powers and Leavitt 3,659,247 Apr. 25, 1972[57] ABSTRACT A modular conductor system for electrical circuit wiring.The system includes a composite insulated conductor assembly havingfirst and second elongate members of substantially homogeneouselectrically nonconductive material, each of the members havingsubstantially uniform transverse dimensions and substantially planarends. The first member includes a plurality of spaced-apart channelseach extending lengthwise of the member in a surface thereof,Electrically conductive members, each having a relatively thinsubstantially uniform cross section fit snugly lengthwise and conform tothe surface of corresponding ones of the channels such that the sideedges of the conductive members are substantially flush with the surfaceof the first elongate member. The second elongate member extends thelength of the first, and has a surface secured to the surface of thefirst member in which the channels extend, confining the conductivemembers in the channels. A space between each of the conductive membersand the surface of the second elongate member defines openings at theends of the composite conductor. Relatively short electricallyconductive connector pins are receivable in the openings for joiningtogether a plurality of the composite conductor assemblies inelectrically conductive relationship. Each of the connector pins has across section conforming to the cross section of the openings at theends of the joined elongate members, the pins having rough surfaces suchthat they are tightly gripped in the openings. Various modules may beused with such composite conductor assemblies, e.g., a receptaclemodule, a switch module, connector modules, and a wiring adaptor modulewhich connects the modular wiring system to wire conductors of a powerdistribution system.

1 1 Claims, 17 Drawing Figures PATENTEDAPR 25 m2 sum 1 I}? 3 PATENTEUAPR25 m2 e59 247 SHEET 2 BF. 3

BACKGROUND OF THE INVENTION This invention relates to electrical circuitwiring systems, and more particularly to a modular conductor system.

For the use of protected electrical circuit wiring, wiring has typicallybeen heretofore carried out by employing metal conduit, armored orsheathed cable, or by enclosing wire conductors in metal molding whichmay be fastened to a wall or the like with clips, etc. Disadvantages ofthese wiring materials are that they may be quite heavy, expensive,cumbersome, and time consuming to install and connect. Furthermore,armored or sheathed cable is not self-supporting, and thus requires theuse of regularly spaced supports such as staples when running lengths ofthe cable. Much of the difficulty in using wiring of this type is thatthe individual wires which are common to each of these approaches mustbe individually cut to length, bared or stripped of its insulation, andthen individually connected, all of which is quite time consuming andthus expensive.

SUMMARY OF THE INVENTION Among the several objects of the presentinvention may be noted the provision of a modular conductor system forelectrical circuit wiring employing composite self-supported insulatedconductor assemblies; the provision of such a system wherein theinsulated conductor assemblies are-quickly and easily installed andconnected; and the provision of such a system wherein a conductorassembly is light in weight, and is easily and inexpensivelyconstructed. Other objects and features will be in part apparent and inpart pointed out hereinafter.

Briefly, the invention contemplates a modular conductor system forelectrical circuit wiring utilizing assemblies each constituted by acomposite insulated conductor. Such an insulated conductor assemblycomprises a first elongate member of substantially homogeneouselectrically nonconductive material having substantially uniformtransverse dimensions and substantially planar ends. A plurality ofspaced-apart channels each extending lengthwise of the member areprovided in a surface thereof. A plurality of electrically conductivemembers, each having a relatively thin, substantially uniform crosssection, fit snugly lengthwise into corresponding ones of the channels,each conforming to the surface of its corresponding channel. Each of theconductive members has side edges substantially flush with the surfacein which the channel extends. A second elongate member, also ofsubstantially homogeneous electrically nonconductive material, extendsthe length of the first elongate member and also has substantiallyplanar ends coinciding with the ends of the first elongate member. Asurface in this second member is secured, as by bonding, to the surfaceof the first member in which the channels extend, thus confining theconductive members in the channels. Thus there is a space between eachof the conductive members and the overlying surface of the secondelongate member. This space defines openings at the ends of thecomposite conductor. A plurality of relatively short electricallyconductive connector pins are receivable in the openings for joiningtogether a plurality of the composite conductors in electricallyconductive relationship. These pins each have a cross section conformingto the cross section of the openings and have rough surfaces so thatthey are tightly gripped in the openings. The invention furthercontemplates a plurality of modules which may be electricallyinterconnected by means of the composite conductor assemblies or towhich power may be provided by the assemblies. Such modules may includea switch module, receptacle modules, connector modules, and a wiringadaptor module for interconnecting the system with conventionalelectrical wire conductors of a power distribution system.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded perspective viewof a composite conductor assembly of the modular conductor system of theinvention;

FIG. 2 is a perspective of an electrically conductive member which ispart of the insulated conductor assembly of FIG. 1;

FIG. 3 is a perspective of portions of a pair of individual compositeconductor assemblies and electrically conductive connector pinsreceivable in openings of the assemblies for joining the assembliestogether in electrically conductive relationship;

FIGS. 4-7 are perspectives of a switch module, a plug receptacle, ascrew-type receptacle, and a wiring adaptor module, respectively, of themodular conductor system of this invention;

FIGS. 8-10 are respective perspectives of three types of connectormodules of the invention;

FIG. 11 is a perspective of a second type of composite conductorassembly utilized in a system of the invention;

FIG. 12 is a transverse section of the conductor assembly of FIG. 11,taken along line 12-12;

FIG. 13 is a perspective of a portion of the wiring adaptor of FIG. 7;

FIG. 14 is a perspective of portions of two composite conductorassemblies, one of the assemblies being provided with certain thermalexpansion compensating structure for thermal expansion, the conductorassemblies being shown with a second type of electrically conductiveconnector pins for electrically interconnecting the assemblies;

FIG. 15 is a section, in perspective, illustrating the provision of acomposite conductor assembly of the invention within a piece ofcomposite flooring material;

FIG. 16 is an exploded perspective of end portions of a pair ofcomposite conductor assemblies of the invention which are adapted forbeing connected together in lap joint configuration; and

FIG. 17 is an exploded assembly of end portions of two coaxial cableassemblies utilizing principles of the present invention, one of theassemblies being shown in section, and illustrating connector sleevesfor electrically interconnecting the conductor assemblies.

Corresponding reference characters indicate corresponding partsthroughout the several views of the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings,and more particularly, to FIGS. 1-3, illustrated generally at 21 is aself-supporting insulated composite conductor of the present inventionwhich is depicted as an exploded assembly. The conductor assembly isconstituted by elongate lower and upper electrically nonconductivemembers designated generally 23 and 25, respectively. As may be seen,members 23 and 25 are of rectangular cross section, although other typesof cross sections may be used. Members 23 and 25 have substantiallyparallel planar ends, the ends of the two members being coincident andperpendicular to the longitudinal axis of the assembly. Thisconstruction permits a plurality of the conductor assemblies to beconnected in end-to-end relationship and also permits interconnection ofone of the assemblies with certain modules of the system which aredescribed hereinbelow.

Preferably, nonconductive members 23 and 25 are of a substantiallyhomogeneous, substantially nonrigid synthetic resin material. Forexample, a semiflexible material such as polystyrene may be utilized, ora more flexible material such as polyethylene may be employed. Lowermember 23 includes a plurality of spaced-apart channels of arcuate formin a surface 27 thereof, each extending lengthwise of member 23. Twosuch channels 29 and 31, of generally semicircular form, areillustrated.

Electrically conductive members or strips 33 and 35, preferably ofaluminum, a highly ductile metal, or a suitable alloy thereof, fitsnugly lengthwise into corresponding ones of channels 29 and 31. Whilealuminum is preferred, other ductile metals having high electricalconductivity, such as copper or alloys thereof may be employed. Tofacilitate construction, aluminum may be extruded into the channels, forexample. Conductive members 33 and 35 have a relatively thinsubstantially uniform arcuate cross section conforming to that of thechannels and have side edges substantially flush with surface 27. As isapparent the conductive members 33 and 35 are of the samecross-sectional shape throughout the length of the channels. A length ofconductive member 35 is shown in FIG. 2.

In the assembled form of conductor assembly 21, upper nonconductivemember 25 has its bottom surface secured to surface 27 of member 23,such as by bonding with epoxy, providing a secure face-to-facerelationship which confines conductive members 33 and 35 in channels 29and 31, respec tively. This assembled condition is depicted in FIG. 3wherein it may be observed that, because of the arcuate form ofconductive members 33 and 35, there is a space between each of theseconductive members and the bottom surface of overlying nonconductivemember 25. The resultant spaces define openings such as designated at 37and 39 at the ends of the composite conductor assembly.

End portions of two identical assemblies are depicted in FIG. 3, theassembly viewed to the left side being designated 21'. Each of openings37 and 39 at the end of assembly 21 has a straight side defined by thebottom surface of member 25 and an arcuate side defined by the interiorsurface of the respective conductive member 33 or 35. Since theseopenings permit conductive members or strips 33 and 35 to be exposed toair, these members are preferably coated with a suitable non-petroleumantioxidant to prevent corrosion or the like.

The composite conductor assembly thus described may be of a suitablelength such as 2, 4 and 8 feet, etc., in order to facilitate electricalcircuit wiring by means of convenient lengths. Such lengths or otherspecific lengths of the composite assembly may be provided by sawing,noting that the preferred plastic and aluminum construction readilyfacilitates sawing. While the use of a substantially non-rigid materialfor the upper and lower non-conductive members permits the bending orsimilar deformation, the assembly is substantially selfsupporting in thesense that reasonable lengths thereof do not sag or droop appreciablyand thus, like conventional conduit, the lengths need only be supportedat relatively distant intervals, e.g., up to several feet. Nonetheless,the lengths can be used in non-linear installations such as on curvingwalls.

To permit joining together of a plurality of the composite conductors,relatively short (e.g., of the order of an inch or two in length)electrically conductive connector pins, such as indicated at 41 and 43,are provided, which are receivable in the openings (such as openings 37and 39) at the ends of the composite conductors. For this purpose, theconnector pins have a semicircular cross section substantially identicalwith, and thus conforming to, the cross section of the openings. Inaddition, the pins are provided with rough surfaces to cause the pins tobe tightly gripped in contact with the conductive members in theopenings. The rough surfaces of the connector pins may be provided byknurling or scoring.

To join together a pair of the composite conductors, the connector pinsmay be inserted in the openings in one of the composite conductors to adistance of about half the length of the pins, and then the othercomposite conductor may be forced onto the pins. To insure centering ofthe pins with respect to a pair of composite conductors, i.e., so thatequal length portions of the pins extend into the openings at the endsof the composite conductors, the connector pins may have a slightlygreater thickness at their midpoints than at their ends, providing aslight taper from the middle portion of the pins toward their ends.

Thus, lengths of composite conductors may be joined together as depictedin FIG. 3 to provide an electrical circuit wiring system in residencesand other structures. In such a system, the invention contemplates theuse of various modules which may be electrically interconnected by meansofthe conductor assemblies or to which power may be supplied by theassemblies.

FIG. 4 illustrates a switch module which may be used in a system of thepresent invention, designated generally 45. Module 45 includes simply aswitch 47 in a suitable enclosure indicated generally l9. This enclosuremay, if desired, be constructed of synthetic resin upper and lowermembers, such as employed for the composite conductor assemblies.Whatever construction is employed, enclosure 49 includes at least oneplanar surface 51 having a pair of openings 53 and 55 aligned withcorresponding openings, such as 37 and 39 in FIG. 3, at the end of thecomposite conductor assembly, these openings 53 and 55 being adapted toreceive the above described connector pins for joining the switch moduleto a composite conductor in electrically conductive relationship, Forthis pur pose, the cross section of openings 53 and 55 is preferably thesame as that of the openings at the ends of a composite conductor. Itshould be understood that switch 47 may be con' stituted by a circuitbreaker. Of course, further openings besides openings 53 and 55 may beprovided in enclosure 49 if desired to permit composite conductors to beconnected from opposite sides of the switch enclosure, for example.

Similar modules are illustrated in FIGS. 5 and 6. FIG. 5 depicts a plugreceptacle module, designated generally 57, and FIG. 6 shows ascrew-type receptacle module, designated generally 59. The constructionof these modules may be like that of switch module 45. For example, thesame type of construction may be used as for the composite conductorassemblies. Each of modules 57 and 59 has a receptacle within anenclosure including at least one planar surface of electricallynonconductive material such as shown at 61 and 63, respectively, havingopenings aligned with corresponding openings of a composite conductor.These openings are adapted to receive the previously described connectorpins and thus preferably have a cross section identical with that of theopenings at the end of the composite conductor.

Module 59 (which may receive a fuze or a light bulb, etc.) includes apair of such openings 65 and 67 identical with openings in surface 63for joining the module to a composite conductor in electricallyconductive relationship. Similarly, module 57 includes a pair of suchopenings 69 and 71 and in addition includes a third opening 73 forconnecting a ground conductor, noting that module 57 is shown as beingof the type for receiving a grounded plug. It should be here understoodthat a composite conductor of the invention may have three conductivemembers (or more), two outer ones being used for a circuit connectionand a middle or inner one being used to provide a circuit ground, suchas has typically been used in residential wiring in recent years.

FIG. 7 illustrates a wiring adapter module, indicated generally 75.Module 75 includes an enclosure indicated generally 77, including means,such as a pair of leads 79 and 81, for providing interconnection withthe usual wire conductors of a power distribution system. Enclosure 77is of any suitable construction but in any case, includes at least oneplanar surface 79 of electrically nonconductive material having a pairof openings 81 and 93 identical with those of the previously describedmodules and which align with corresponding openings at one end of acomposite conductor so as to receive connector pins for electricallyconnecting the conductive members of a composite conductor to the wireconductors of a power distribution system.

One preferred construction of wiring adapter module 75 is illustrated inFIG. 13. Enclosure 75 (FIG. 7) is shown in FIG. 13 as having a lowermember 85, of synthetic resin material there being an upper member notshown in FIG. 13 which also is preferably synthetic resin material andhas a rectangular cross section, the upper member being otherwiseidentical to a length of an upper member of a composite conductor of theinvention. Member 85 also is substantially identical with a length ofalower member ofa composite conductor. Member 85 is provided with a pairof spaced-apart channels 87 and 89 extending lengthwise of the memberbut terminating short of one end of the member, unlike the compositeconductor construction. A pair of electrically conductive strip members91 and 93 like those described previously fit snugly into channels 87and 89 respectively. The pair of leads 79 and 81 extend throughrespective holes 95 and 97 at the latter end of member 85 and terminatein suitable conductive fittings 96 and 98 respectively, which aresecured in electrically conductive relationship as by soldering, etc. tomembers 91 and 93. As in the construction of a composite conductor ofthe invention the upper member corresponding to lower member 85 issuitably bonded or secured to the latter to securely retain stripmembers 91 and 93 in the channels.

The invention contemplates the use of various connector modules such asillustrated in FIGS. 8-10 for the purpose of connecting together aplurality of composite conductors and for providing for the installationof lengths of the composite conductors at various angles with respect tothe different lengths, as may be required for corners and irregularshapes.

FIG. 8 depicts a connector module, indicated generally at 101, forproviding a four-way junction of composite conductors, there being fourplanar surfaces such as surface 103 which are of electricallynonconductive material each having openings such as 105 and 107 alignedwith openings ofa composite conductor to permit the receiving of theconductor pins to provide for joining a plurality of compositeconductors in electrically conductive relationship. The constructionused for module 101 is preferably similar to that employed for thecomposite conductors.

In the use of a junction connector such as that represented by module101, it will be seen that, if a construction is used which is like thatof the composite conductors, the conductive members which extend to theedges of openings such as 105 and 107 will be exposed, providing apotential shock hazard if a composite conductor is not connected at thatlocation. To prevent this shock hazard, a plug 109 of electricallynonconducting material, e.g., polystyrene, may be employed if acorporate conductor is not to be connected at openings 105 and 107. Plug109 has integral pins or prongs 111 and 113 which fit into the exposedopenings, e.g., openings 105 and 107, thereby preventing inadvertenttouching of any exposed electrically live members.

Connector modules for providing for joining composite conductors at 90and 45 angles, for example, are the subjects of FIGS. 9 and 10, and aredesignated generally 115 and 117, respectively. Preferably theirconstruction is similar to module 101 and to the composite conductors.Other types of modules for different angles, for providing offsets, etc.are also possible and theconstructions shown in FIGS. 8-10 are shownmerely by way of example.

FIGS. 11 and 12 are illustrative of another embodiment ofa compositeconductor assembly of the invention and one which is particularly usefulfor being used along walls or the like similar to conventionalquarter-round molding. The assembly, designated generally 119, includesupper and lower members 121 and 123, respectively, of substantiallyhomogeneous electrically nonconductive material, e.g., polystyrene orpolyethylene, having substantially uniform transverse dimensions. Whileonly a portion of the length of such a composite conductor is shown, itwill be seen that, as in the previously described form, members 121 and123 have substantially parallel planar ends. Suitable lengths, e.g., 2,4 or 8 feet, etc. may be constructed in this form.

Member 121 includes a pair of spaced-apart arcuate channels 125 and 127extending lengthwise of the member in which extend electricallyconductive members 129 and 131, respectively. The latter are preferablyof aluminum and are otherwise substantially identical with theircounterparts employed in the previously described composite conductorembodiment. These conductive members are fitted snugly into theirrespective channels with their side edges substantially flush with theinterior surface of member 121 and are thus securely held in position bymember 123 when the latter is secured to member 121.

Composite conductor 119 is shown including a plug receptacle 133 whichmay be molded into member 121 to provide a pair of openings 135 and 137for receiving the prongs of a conventional plug. As illustrated in FIG.12, openings 131 and 133 extend in parallel relationship through member121 to permit prongs of a plug to engage conductive members 129 and 131.

Lengths of the above-described composite conductor may be joinedtogether by means of connector pins such as those previously describedby inserting the pins into the openings, such as openings 139 and 141,at the ends of the composite conductor.

FIG. 14 illustrates additional features of the invention in depictingtwo lengths of composite conductors designated generally 139 and 141.The upper nonconductive members of assemblies 139 and 141 are not shownbut are identical with corresponding parts shown in FIGS. 1 and 3. Theleft side assembly 139 (shown in broken section) is viewed as inposition for being joined to assembly 141 by means of connector pins ofa form different from that previously described. As may be seen, theconnector pins, designated 143 and 145, are of relatively thinsubstantially uniform cross section and are arcuate in form, as comparedwith the semicylindrical cross section of the corresponding pins 41 and43 of FIG. 3. However, like the latter, pins 143 and 145 have a crosssection corresponding to the cross section of the openings at the endsof a composite conductor so as to be received and tightly gripped bythese openings. Aside from their thin cross section, pins 143 and 145are substantially identical with the connector pins 41 and 43 of FIG. 3.

The left-most section of assembly 139 includes a thermal expansionfeature of the invention which may be desired if long lengths ofcomposite conductors are employed in a location where extremes intemperature may cause significant changes in the length of theconductive members of a composite conductor. This particular section ofassembly 139 has a lower member 147 in which conductive members such asthose designated 149 and 151 are disposed end-to-end within the channelsto provide expansion gaps, such as gap 153, between the adjacent ends ofthe conductive members. Each pair of the adjacent ends is bridged by afurther conductive member, such as member 155, overlapping a marginalportion of each of the adjacent ends. Member 155 has a relatively thinuniform cross section and fits snugly lengthwise into the space betweenthe conductive members 149 and 151 and the flat surface of the uppermember (not shown). As is apparent, the side edges of member 155 aresubstantially flush with those of members 149 and 151 and thus also withthe channeled surface of nonconductive lower member 147. The expansiongap allows for any changes in length of the principal conductive membersso that they do not cause undue thermal stress in the compositeconductor.

FIG. 15 illustrates an advantage of the invention in showing in sectiona piece of composition flooring material 157 having a channel ofrectangular cross section in the underside thereof of depth and widthsubstantially the same as those of a composite conductor of theinvention. A composite conductor 159 is shown fitted into the channel.In this way lengths of the composite conductors are convenientlyinstalled beneath a floor.

FIG. 16 depicts composite conductors of the invention, designated 161and 163 generally, providing a half-lap configuration for joining thecomposite conductors together. Each of the composite conductors 161 and163 is seen to have a respective first half member 165, 167 with planarends and having six conductive members or strips (such as previouslydescribed) positioned in arcuate channels in a surface thereof. Eachcomposite conductor has a respective second half member 169, 171 whichoverlies the conductive members and is joined to the first half memberbut which terminates short of the end of the respective first halfmember 165, 167 to provide exposed terminal portions of the conductivemembers. As is apparent, the composite conductors 161 and 163 areoppositely oriented so that when placed together, the exposed portionsof conductive members of composite conductor 161 come into electricalcontact with the exposed portions of corresponding ones of theconductive members of composite conductor 163. The composite conductorsmay then be suitably clamped, etc., to provide a strong half-lapconnection having good electrical characteristics.

The principles of the invention may be applied in the manufacturecomposite coaxial conductor assemblies configured as shown in FIG. 17.Terminal portions oflengths ofsuch coaxial assemblies are indicatedgenerally 171 and 173. Portion 171 is shown in section and includes anelectrically nonconductive cylindrical outer shell 175 of a suitablesynthetic resin material which may be semiflexible and, as in thepreviously described embodiment, is a substantially homogeneousmaterial. Positioned snugly within outer shell 175 is a first relativelythin tubular outer conductor 177 of electrically conductive material(which may be of aluminum or an alloy thereof, for example). Acylindrical inner shell 179 is positioned within conductor 177 and ispreferably of the same nonconductive material as shell 175. A thintubular inner conductor 181 is snugly positioned within inner shell 179.Conductor 181 may also be of aluminum, for example. Snugly positionedwithin conductor 181 and fitting the bore thereof, is a core 184 alsopreferably of the same nonconductive material as shell 175.

The lengths of coaxial conductor assembly are joined together inelectrically conductive relationship by a pair of thin conductiveconnector sleeves 185 and 187, each having a rough outer surface, asillustrated, such as may be provided by burring, scoring or knurling, etcetera. Connector sleeves 185 and 187 may be of the same type of metalor conductive material as conductors 177 and 181. To permit electricalinterconnection of the latter conductors of the lengths of coaxialassemblies, the inner sleeve and the core each has a recess ofa depthsufficient to permit receiving at least half the length ofa respectiveone of the conductor sleeves so that the sleeve is in electrical contactwith the respective conductor of the coaxial assembly. For example, inassembly 171 inner shell 179 includes a concentric recess 189 adjacentconductor 177 for receiving connector sleeve 185 and core 183 includes aconcentric recess 191 adjacent conductor 181 for receiving sleeve 185.Identical recesses are provided at the opposite end of assem bly 171corresponding with the illustrated end of assembly 173. Thecorresponding recesses and sleeves are of substantially identicalcross-section as is apparent.

There are identical recesses in assembly 173, as shown, and thus the twolengths of coaxial conductor assembly are readily interconnected inelectrically conductive relationship by means of the sleeves, therespective diameters of the latter being such as to cause their roughouter surfaces to be tightly received in these recesses. To minimizedeleterious effects of the sleeves upon the transmission characteristicsof the coaxial assembly at radio frequencies the sleeves may be quitethin, or their length and thickness may be taken into account usingconventional transmission line considerations. By utilizing asubstantially nonrigid material for outer shell 175, inner shell 179,and core 183, limited bending of the composite assembly isadvantageously permitted yet the assembly is substantiallyself-supporting.

In view of the above, it will be seen that the several objects of theinvention are achieved and other advantageous results attained.

As various changes could be made in the above constructions withoutdeparting from the scope of the invention, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

What is claimed is:

1. In a modular conductor system for electrical circuit wiring, anassembly constituting a composite insulated conductor comprising:

a first elongate member of substantially homogeneous electricallynonconductive material, said member having substantially uniformtransverse dimensions and substantially planar ends, said member havinga plurality of spacedapart channels of arcuate form each extendinglengthwise of said member in a surface thereof;

a plurality of electrically conductive members, each having a relativelythin substantially uniform cross section of arcuate form, each fittingsnugly lengthwise into a corresponding one of said channels andconforming to the surface of the corresponding channel, said conductivemembers being of the same cross-sectional shape throughout the length ofsaid channels and having side edges substantially flush with the surfaceof said elongate member in which surface said channels extend, saidconductive members extending substantially to the ends of said firstelongate member;

a second elongate member of substantially homogeneous electricallynonconductive material extending the length of said first elongatemember and having substantially planar ends coinciding with the ends ofsaid first elongate member and a surface secured to the surface of saidfirst elongate member in which said channels extend for confining saidconductive members in said channels, there being a space between each ofsaid conductive members and said surface of said second elongate memberwhich space defines openings at the ends of said composite conductor,said openings each having a straight side and an arcuate side; and

plurality of relatively short electrically conductive connector pinsreceivable in said openings for joining together a plurality ofcomposite conductors in electrically conductive relationship, said pinseach having a cross section conforming to the cross section of each ofsaid openings, said pins each having rough surfaces to be tightlygripped in contact with said conductive members in said openings.

2. In a modular conductor system as set forth in claim 1, saidconductive members comprising a ductile metal.

3. In a modular conductive system as set forth in claim 2, saidconductive members comprising aluminum.

4. In a modular conductor system as set forth in claim 1, the crosssection of each of said pins being substantially identical with thecross section of each of said openings 5. In a modular conductor systemas set forth in claim 1, the cross section of said pins being relativelythin and substantially uniform.

6. In a modular conductor system as set forth in claim 1, said first andsecond elongate members comprising a substantially nonrigid material.

7. In a modular conductor system as set forth in claim 1, there being aplurality of said conductive members disposed end-to-end in each of saidchannels providing an expansion gap between adjacent ends of saidconductive members in each channel, each pair of said adjacent endsbeing bridged by a further conductive member overlapping a marginalportion of each of said adjacent ends, having a relatively thinsubstantially uniform cross section of arcuate form, and fitting snuglylengthwise into the space between the first said conductive members andthe flat surface of said second elongate member, the side edges of saidfurther member being substantially flush with said surface in which saidchannels extend, whereby thermal expansion of the first said conductivemembers does not cause undue thermal stress in said composite conductor.

8. In a modular conductor system as set forth in claim 1, a switchmodule comprising electrical switch means in an enclosure, saidenclosure having at least one planar surface of electricallynonconductive material, said surface having a plurality of openingsaligned with corresponding openings at one end of said compositeconductor and adapted to receive said pins for joining said switchmodule to said composite conductor in electrically conductiverelationship,

9. In a modular conductor system as set forth in claim 1, a receptaclemodule comprising a receptacle in an enclosure, said enclosure having atleast one planar surface of electrically nonconductive material, saidsurface having a plurality of openings which align with correspondingopenings at one end of said composite conductor and which receive saidpins for joining said receptacle module to said composite conductor inelectrically conductive relationship.

10. In a modular conductor system as set forth in claim 1, a connectormodule for connecting together a plurality of the composite conductors,said module having a plurality of planar surfaces each of which includesa plurality of openings which align with corresponding ones of openingsat an end of one of the plurality of composite conductors and whichreceive said pins for joining the plurality of composite conductors inelectrically conductive relationship.

11. In a modular conductor system as set forth in claim 1, a wiringadapter module comprising an enclosure including means for providinginterconnection with wire conductors of a power distribution system,said enclosure having at least one planar surface of electricallynonconductive material, said surface having a plurality of openingswhich align with corresponding openings at one end of said compositeconductor and which receive said pins for electrically connecting saidconductive member to the last-said means which said conductive membersare electrically interconnected with said wire conductors of a powerdistribution system.

1. In a modular conductor system for electrical circuit wiring, anassembly constituting a composite insulated conductor comprising: afirst elongate member of substantially homogeneous electricallynonconductive material, said member having substantially uniformtransverse dimensions and substantially planar ends, said member havinga plurality of spaced-apart channels of arcuate form each extendinglengthwise of said member in a surface thereof; a plurality ofelectrically conductive members, each having a relatively thinsubstantially uniform cross section of arcuate form, each fitting snuglylengthwise into a corresponding one of said channels and conforming tothe surface of the corresponding channel, said conductive members beingof the same cross-sectional shape throughout the length of said channelsand having sidE edges substantially flush with the surface of saidelongate member in which surface said channels extend, said conductivemembers extending substantially to the ends of said first elongatemember; a second elongate member of substantially homogeneouselectrically nonconductive material extending the length of said firstelongate member and having substantially planar ends coinciding with theends of said first elongate member and a surface secured to the surfaceof said first elongate member in which said channels extend forconfining said conductive members in said channels, there being a spacebetween each of said conductive members and said surface of said secondelongate member which space defines openings at the ends of saidcomposite conductor, said openings each having a straight side and anarcuate side; and a plurality of relatively short electricallyconductive connector pins receivable in said openings for joiningtogether a plurality of composite conductors in electrically conductiverelationship, said pins each having a cross section conforming to thecross section of each of said openings, said pins each having roughsurfaces to be tightly gripped in contact with said conductive membersin said openings.
 2. In a modular conductor system as set forth in claim1, said conductive members comprising a ductile metal.
 3. In a modularconductive system as set forth in claim 2, said conductive memberscomprising aluminum.
 4. In a modular conductor system as set forth inclaim 1, the cross section of each of said pins being substantiallyidentical with the cross section of each of said openings.
 5. In amodular conductor system as set forth in claim 1, the cross section ofsaid pins being relatively thin and substantially uniform.
 6. In amodular conductor system as set forth in claim 1, said first and secondelongate members comprising a substantially nonrigid material.
 7. In amodular conductor system as set forth in claim 1, there being aplurality of said conductive members disposed end-to-end in each of saidchannels providing an expansion gap between adjacent ends of saidconductive members in each channel, each pair of said adjacent endsbeing bridged by a further conductive member overlapping a marginalportion of each of said adjacent ends, having a relatively thinsubstantially uniform cross section of arcuate form, and fitting snuglylengthwise into the space between the first said conductive members andthe flat surface of said second elongate member, the side edges of saidfurther member being substantially flush with said surface in which saidchannels extend, whereby thermal expansion of the first said conductivemembers does not cause undue thermal stress in said composite conductor.8. In a modular conductor system as set forth in claim 1, a switchmodule comprising electrical switch means in an enclosure, saidenclosure having at least one planar surface of electricallynonconductive material, said surface having a plurality of openingsaligned with corresponding openings at one end of said compositeconductor and adapted to receive said pins for joining said switchmodule to said composite conductor in electrically conductiverelationship.
 9. In a modular conductor system as set forth in claim 1,a receptacle module comprising a receptacle in an enclosure, saidenclosure having at least one planar surface of electricallynonconductive material, said surface having a plurality of openingswhich align with corresponding openings at one end of said compositeconductor and which receive said pins for joining said receptacle moduleto said composite conductor in electrically conductive relationship. 10.In a modular conductor system as set forth in claim 1, a connectormodule for connecting together a plurality of the composite conductors,said module having a plurality of planar surfaces each of which includesa plurality of openings which align with corresponding ones of openingsat an end of one of the pluraLity of composite conductors and whichreceive said pins for joining the plurality of composite conductors inelectrically conductive relationship.
 11. In a modular conductor systemas set forth in claim 1, a wiring adapter module comprising an enclosureincluding means for providing interconnection with wire conductors of apower distribution system, said enclosure having at least one planarsurface of electrically nonconductive material, said surface having aplurality of openings which align with corresponding openings at one endof said composite conductor and which receive said pins for electricallyconnecting said conductive member to the last-said means which saidconductive members are electrically interconnected with said wireconductors of a power distribution system.